Method of incorporating an additive into a polymer composition and dispersion used therein

ABSTRACT

A method of incorporating an additive into a polymer composition includes the step of melt blending a polymer with a dispersion comprising a liquid carrier, an unmodified clay, and an additive. Using the dispersion rather than a polymer-based additive masterbatch saves energy. Like a polymer-based masterbatch, the dispersion provides the additive in a diluted form and therefore preserves the masterbatch&#39;s advantages of providing more uniform distribution additive in the plastic and avoiding direct handling of additives in the final compounding step. The dispersion is also described.

BACKGROUND OF THE INVENTION

Many plastics are provided as blends that include not only plastic resin but also one or more additives that improve the appearance and/or properties of the plastic. For example, certain electrically conductive blends of polyamide and poly(arylene ether) resins are used to fabricate electrostatically painted automotive parts. The electrical conductivity of these blends is provided by a small amount of carbon nanotubes present as an additive in the blends. In order to improve the uniformity of additive distribution in the plastic and, in some cases, to avoid direct handling of the additive in the final compounding step, the additive is often incorporated into an intermediate plastic composition, known as a masterbatch, and the masterbatch is then combined with other components to form the final plastic composition.

The formation of the masterbatch requires a separate melt blending step that is energy intensive. There is therefore a desire for a less energy intensive means of incorporating additives into plastics, while still preserving the masterbatch's advantages of providing more uniform distribution additive in the plastic and avoiding direct handling of additives in the final compounding step.

BRIEF DESCRIPTION OF THE INVENTION

One embodiment is a method of incorporating an additive into a polymer composition, comprising: melt blending a polymer with a dispersion comprising a liquid carrier, an unmodified clay, and an additive.

Another embodiment is a dispersion, comprising: about 83 to about 98 weight percent of water; about 1 to about 10 weight percent of an unmodified clay; and about 1 to about 7 weight percent of carbon nanotubes; wherein the weight percents of the water, the unmodified clay, and the carbon nanotubes are based on the weight of the dispersion.

Other embodiments, including polymer compositions prepared by the method, and articles comprising the polymer compositions, are described in detail below.

DETAILED DESCRIPTION OF THE INVENTION

The present inventors have found that additives can be efficiently incorporated into plastic compositions by first forming a specific dispersion of the additive, then melt blending the dispersion with the plastic resin (polymer) and any other optional components. Thus, one embodiment is a method of incorporating an additive into a polymer composition, comprising: melt blending a polymer with a dispersion comprising a liquid carrier, an unmodified clay, and an additive. Forming the dispersion is significantly less energy intensive than forming a corresponding additive masterbatch, with energy savings resulting both from a lower preparation temperature and from reduction in the mechanical energy required for mixing. Like a masterbatch, the dispersion provides the additive in a diluted form and therefore preserves the masterbatch's advantages of providing more uniform distribution of additive in the plastic and avoiding direct handling of additive in the final compounding step.

Melt blending of the polymer and the dispersion is typically conducted at a temperature that is above the glass transition temperature and/or melting temperature of the polymer(s) employed, provided that the temperature is not so high as to cause undesired decomposition of the polymer(s) and/or additive(s). For example, for blends of poly(arylene ether) and polyamide, melt blending is typically conducted at a temperature of about 270 to about 320° C., specifically about 280 to about 310° C., more specifically about 290 to about 300° C. The term “undesired decomposition” is intended to exclude desired reactions between components, such as the desired compatibilization reaction between a poly(arylene ether), a polyamide, and, optionally, a compatibilizing agent such as citric acid. Apparatus for melt blending is known in the art and includes, for example, Brabender mixers and extruders, including single-screw extruders and twin-screw extruders.

In some embodiments, melt blending is conducted under conditions effective to evaporate the liquid carrier. For example, when the liquid carrier is water and melt blending is conducted in an extruder, some or essentially all of the free (unbound) water provided by the dispersion can be removed from the melt blended composition via venting of the extruder. In some embodiments, the extruder is equipped with one or more so-called vacuum vents that are maintained at sub-atmospheric pressure to facilitate removal of the liquid carrier from the compounded composition. Thus, in some embodiments, it is possible to evaporate (remove) at least 90 weight percent, or at least 95 weight percent, or at least 98 weight percent of the free liquid carrier from the composition. In this context, it will be understood that “free liquid carrier” does not include any liquid carrier that is bound to another component of the composition, such as water bound to the unmodified clay.

Alternatively, in some embodiments, melt blending is conducted under conditions such that substantially all of the liquid carrier remains in the compounded composition. For example, when the liquid carrier is mineral oil, it typically will remain in the compounded composition.

A wide variety of polymers can be used, including thermoplastics, thermoplastic elastomers, elastomers, and thermosets, provided that melt blending of thermosets is conducted under conditions not effective to substantially cure the thermosets. Thermoplastics include, for example, polycarbonates, polyesters (such as poly(ethylene terephthalate), amorphous poly(ethylene terephthalate), and poly(butylene terephthalate)), polyamides (such as polyamide-1,1, polyamide-1,2, polyamide-4,6, polyamide-4T, polyamide-6, polyamide-6,6, polyamide-6,10, polyamide-6,12, polyamide-6T, polyamide-6I, polyamide-9T, polyphthalamide), polyimides, polyetherimides, polyurethanes, polystyrenes, poly(arylene ether)s, poly(phenylene sulfide)s, polyarylsulfones, polyethersulfones, poly(ether ketone)s, poly(ether ether ketone)s, polyacrylates (such as poly(methyl methacrylate) and poly(butyl acrylate)), poly(vinyl butyral), polyethylenes (such as high density polyethylenes, low density polyethylenes, and linear low density polyethylenes), chlorinated polyethylenes, polytetrachloroethylenes, polypropylenes, poly(vinyl acetate), polyacrylonitriles, poly(vinyl chloride), poly(vinyl fluoride), poly(vinylidene fluoride), polytetrafluoroethylenes, copolymers comprising repeats unit derived from ethylene, copolymers comprising repeat units derived from propylene, copolymers comprising repeat units derived from styrene, copolymers of ethylene and polytetrafluoroethylene, copolymers of vinylidene chloride and vinyl chloride, copolymers of vinyl acetate and vinylidene chloride, copolymers of styrene and acrylonitrile, copolymers of alpha-methylstyrene and acrylonitrile, polyacetals, and the like, and combinations thereof. Thermoplastic elastomers include, for example styrenic block copolymers (such as polystyrene-polybutadiene block copolymers, polystyrene-poly(ethylene-propylene) block copolymers, and polystyrene-poly(ethylene-butylene) block copolymers), polyolefin blends, elastomeric alloys (including thermoplastic vulcanizates), thermoplastic polyurethanes, thermoplastic copolyesters, rubber-modified polystyrenes, and the like, and combinations thereof. Elastomers include natural rubber, polybutadienes, polyisoprenes, copolymers of isobutylene and isoprene, copolymers of styrene and butadiene (styrene-butadiene rubber), copolymers of butadiene and acrylonitrile, copolymers of acrylonitrile and styrene and acrylate esters, copolymers of acrylonitrile and butadiene and styrene, polychloroprenes, copolymers of ethylene and propylene (ethylene-propylene rubber), polysiloxanes, fluorosilicone rubbers, polyether block amides, copolymers of ethylene and vinyl acetate, and the like, and combinations thereof. Thermosets include, for example, melamine, epoxy resins, cyanate ester resins, maleimide resins, benzoxazine resins, vinylbenzyl ether resins, alkene-containing monomers, alkyne-containing monomers, arylcyclobutene resins, perfluorovinyl ether resins, and oligomers and polymers with curable vinyl functionality, and combinations thereof.

In some embodiments, the polymer is selected from the group consisting of polyesters, melamines, poly(vinyl chloride)s, polystyrenes, polyethylenes, chlorinated polyethylenes, polytetrachloroethylenes, polypropylenes, polycarbonates, polyimides, polyetherimides, poly(ether ether ketone)s, polysulfones, poly(arylene ether)s, polyamides, copolymers of styrene and acrylonitrile, copolymers of alpha-methylstyrene and acrylonitrile, copolymers of acrylonitrile and butadiene and styrene, copolymers of acrylonitrile and styrene and acrylate esters, polyacetals, copolymers of ethylene and polytetrafluoroethylene, rubber-modified polystyrenes, polyurethanes, and combinations thereof.

The polymer is melt blended with a dispersion that comprises a liquid carrier, an unmodified clay, and an additive. Suitable liquid carriers include, for example, water, C₁-C₁₈ alcohols (including methanol, ethanol, n-propanol, and isopropanol), C₂-C₁₈ aldehydes (including acetaldehyde), C₃-C₁₈ ketones (including acetone and methyl ethyl ketone), C₃-C₁₈ esters (including ethyl acetate), C₂-C₁₈ ethers (including diethyl ether and tetrahydrofuran), mineral oils, organic oils, C₄-C₁₈ aliphatic hydrocarbon solvents (including pentanes, hexanes, and heptanes), C₆-C₁₈ aromatic hydrocarbon solvents (including benzene, toluene, and xylenes), liquidized gases (including supercritical fluids such as supercritical carbon dioxide), and mixtures thereof.

In some embodiments, the liquid carrier comprises water. In some embodiments, the liquid carrier comprises water in an amount of at least 90 weight percent, or at least 95 weight percent, or at least 98 weight percent, or at least 99 weight percent, based on the weight of the liquid carrier. In some embodiments, the liquid carrier consists of water.

In some embodiments, the dispersion comprises the liquid carrier in an amount of about 80 to about 98.9 weight percent, based on the weight of the dispersion. Within this range, the liquid carrier amount can be about 85 to about 98.5 weight percent, specifically about 87 to about 98 weight percent, more specifically about 91 to about 96 weight percent, even more specifically about 91 to about 94 weight percent.

In addition to the liquid carrier, the dispersion comprises an unmodified clay. In this context, “unmodified” means that the clay has not been treated with an agent to increase its hydrophobicity. Thus, the term “unmodified clay” exclude so-called organoclays. Unmodified clays can have chemical compositions identical to those of naturally occurring mineral forms. However, unmodified clays can further include clays that have been physically or chemically treated, as long as such chemical treatment does not include treatment with an agent to increase the hydrophobicity of the clay. Thus, included among unmodified clays are clays that have been treated to effect exchange of a naturally occurring inorganic counterion for another inorganic counterion. For example, one unmodified clay is the product of treating a natural montmorillonite to substitute protons or potassium counterions for naturally occurring sodium counterions.

Unmodified clays include, for example, kaolinite, dicktite, nacrite, pyrophyllite, talc, vermiculite, sauconite, saponite, nontronite, montmorillonite, illite, amesite, baileychlore, chamosite, clinochlore (kaemmererite), cookeite, corundophilite, daphnite, delessite, gonyerite, nimite, odinite, orthochamosite, penninite, pannantite, rhipidolite (prochlore), sudoite, thuringite, and mixtures thereof.

In some embodiments, the unmodified clay comprises montmorillonite. In some embodiments, the unmodified clay comprises montmorillonite in an amount of at least 90 weight percent, or at least 95 weight percent, or at least 98 weight percent, or at least 99 weight percent, based on the weight of the unmodified clay. In some embodiments, the unmodified clay consists of montmorillonite.

In some embodiments, the dispersion comprises the unmodified clay in an amount of about 1 to about 10 weight percent, based on the weight of the dispersion. Within this range, the unmodified clay amount can be about 2 to about 8 weight percent, specifically about 3 to about 6 weight percent, more specifically about 3 to about 5 weight percent.

Although the method has been described as utilizing an unmodified clay, it will be understood that it is possible to substitute alternative rheological modifiers for the unmodified clay. Other suitable rheological modifiers include the synthetic inorganic materials sold by Rockwood Additives as LAPONITE RD, LAPONITE RDS, LAPONITE S482, and LAPONITE SL25; and natural smectites, including those sold by Rockwood Additives as OPTIGEL CK, OPTIGEL CL, OPTIGEL CG, and OPTIGEL CMO.

In addition to the liquid carrier and the unmodified clay, the dispersion comprises an additive. Suitable additives include, for example, colorants (including dyes and pigments), electrically conductive agents (including carbon blacks and carbon nanotubes), stabilizers, antioxidants, mold release agents, flame retardants, drip retardants, UV blockers, fragrances, anti-static agents, metal deactivators, antiblocking agents, impact modifiers, and fillers (including minerals, glass fibers and carbon fibers). In a given dispersion, the additive is distinct from the unmodified clay. Thus, an unmodified clay cannot serve as both the dispersion's unmodified clay and its mineral filler additive.

In some embodiments, the additive comprises conductive carbon black, carbon nanotubes, or a combination thereof. In some embodiments, the additive comprises carbon nanotubes. In some embodiments, the additive comprises carbon nanotubes in an amount of at least 90 weight percent, or at least 95 weight percent, or at least 98 weight percent, or at least 99 weight percent, based on the weight of the additive. In some embodiments, the additive consists of carbon nanotubes.

The carbon nanotubes used can undergo roping and can be single wall carbon nanotubes (SWNTs) and/or multiwall carbon nanotubes (MWNTs). Carbon nanotubes used in the carbon nanotube composition may be produced by laser-evaporation of graphite, chemical vapor deposition, carbon arc synthesis, or the high-pressure carbon monoxide conversion process (HIPCO) process.

The SWNTs generally have a single wall comprising a graphene sheet with outer diameters of about 0.7 to about 2.4 nanometers. It is generally desirable for the SWNTs to have an inherent thermal conductivity of at least 2000 Watts per meter Kelvin (W/m-K) and for the SWNT ropes to have an inherent electrical conductivity of 10⁴ Siemens/centimeter (S/cm). It is also generally desirable for the SWNTs to have a tensile strength of at least 80 gigapascals (GPa) and a stiffness of at least about 0.5 tarapascals (TPa).

In another embodiment, the SWNTs may comprise a mixture of metallic nanotubes and semi-conducting nanotubes. Metallic nanotubes are those that display electrical characteristics similar to metals, while the semi-conducting nanotubes are those that are electrically semi-conducting. In general the manner in which the graphene sheet is rolled up produces nanotubes of various helical structures. Zigzag and armchair nanotubes constitute the two possible confirmations. In order to minimize the quantity of SWNTs utilized in the composition, it is generally desirable to have the metallic nanotubes constitute a large fraction of the total amount of SWNTs used in the composition. It is generally desirable for the SWNTs used in the composition to comprise metallic nanotubes in an amount of greater than or equal to about 1 wt % of the total weight of the SWNTs. In one embodiment, it is desirable to have metallic nanotubes in an amount of greater than or equal to about 20 weight percent, while in another embodiment, it is desirable to have metallic nanotubes in an amount of greater than or equal to about 30 weight percent of the total weight of the SWNTs. In yet another embodiment, it is desirable to have metallic nanotubes in an amount of greater than or equal to about 50 weight percent, while in another embodiment, it is desirable to have metallic nanotubes in an amount of greater than or equal to about 99.9 weight percent of the total weight of the SWNTs.

The MWNTs generally have multiple walls comprising graphene sheet with outer diameters of about 1.4 to about 500 nanometers (nm). MWNTs have at least two graphene layers bound around at least a portion of an inner hollow core. In one embodiment, the MWNTs may have only two graphene layers, while in another embodiment, the MWNTs may have only three graphene layers. MWNTs having only two graphene layers are termed double wall carbon nanotubes, while MWNTs having only three graphene layers are termed triple wall carbon nanotubes. Hemispherical caps generally close both ends of the MWNTs, but it may desirable to use MWNTs having only one hemispherical cap or MWNTs, which are devoid of both caps. It is generally desirable to use MWNTs having average diameters less than or equal to about 40 nanometers. In one embodiment, it is desirable to use MWNTs having diameters of less than or equal to about 30 nanometers, while in another embodiment it is desirable to use MWNTs having diameters less than or equal to about 20 nanometers.

Carbon nanotubes having aspect ratios of greater than or equal to about 5 are generally utilized. In some embodiments, the aspect ratio is greater than or equal to 100, while in other embodiments, the aspect ratio is greater than or equal to 1,000. The carbon nanotubes generally comprise a central portion, which is hollow, but can be filled with amorphous carbon.

It will be understood that the polymer composition can include additives in addition to those provided by the dispersion. Thus, any of the additives listed above can be separately added during melt blending of the polymer and the dispersion.

The amount of the additive in the dispersion will depend on factors including the additive type, the effect of the additive on the dispersion rheology, and the desired amount of additive in the final polymer composition. In some embodiments, the dispersion comprises the additive in an amount of about 0.1 to about 10 weight percent, based on the weight of the dispersion. Within this range, the additive amount can be about 0.5 to about 8 weight percent, specifically about 1 to about 6 weight percent, more specifically about 2 to about 5 weight percent, even more specifically about 3 to about 4 weight percent.

In some embodiments, the dispersion comprises about 80 to about 98.9 weight percent of the liquid carrier, about 1 to about 10 weight percent of the unmodified clay, and about 0.1 to about 10 weight percent of the additive, wherein the weight percents of the liquid carrier, the unmodified clay, and the additive are based on the weight of the dispersion. Within the range of about 80 to about 98.9 weight percent, the liquid carrier amount can be about 85 to about 98.5 weight percent, specifically about 87 to about 98 weight percent, more specifically about 91 to about 96 weight percent, even more specifically about 91 to about 94 weight percent. Within the range of about 1 to about 10 weight percent, the unmodified clay amount can be about 2 to about 8 weight percent, specifically about 3 to about 6 weight percent, even more specifically about 3 to about 5 weight percent. Within the range of about 0.1 to about 10 weight percent, the additive amount can be about 0.5 to about 8 weight percent, specifically about 1 to about 6 weight percent, more specifically about 2 to about 5 weight percent, even more specifically about 3 to about 4 weight percent.

The dispersion can be prepared simply by mixing the liquid carrier, the unmodified clay, and the additive. In some embodiments, all of the additive is mixed with a portion of the liquid carrier (e.g., ca. 40 to about 80 weight percent of the liquid carrier) and a portion of the unmodified clay (e.g., ca. 30 to about 70 weight percent of the unmodified clay) to form an intermediate mixture with which the remainder of the liquid carrier and the remainder of the clay are subsequently mixed. In some embodiments, the dispersion is allowed to age before use. In some embodiments, the aging time is about 10 to about 40 hours at ambient temperature (e.g., 25° C.). In other embodiments, the aging time is about 30 minutes to about 5 hours at elevated temperature (e.g., 40 to 80° C.). Aging can be accompanied by hydration of the unmodified clay.

In some embodiments, the dispersion has a viscosity of about 10 to about 1,000,000 centipoise, specifically about 100 to about 100,000 centipoise, more specifically about 1,000 to about 10,000 centipoise, as measured at 25° C. and a shear rate in the range of about 50 to about 450 sec⁻¹.

In a very specific embodiment, the liquid carrier comprises water, the dispersion comprises about 83 to about 98 weight percent of the liquid carrier, the unmodified clay comprises montmorillonite, the dispersion comprises about 1 to about 10 weight percent of the unmodified clay, the additive comprises carbon nanotubes, the dispersion comprises about 1 to about 7 weight percent of the additive, wherein the weight percents of the liquid carrier, the unmodified clay, and the additives are based on the weight of the dispersion. Within the range of about 83 to about 98 weight percent, the liquid carrier amount can be about 87 to about 96 weight percent, specifically about 91 to about 94 weight percent. Within the range of about 1 to about 10 weight percent, the unmodified clay amount can be about 2 to about 8 weight percent, specifically about 3 to about 5 weight percent. Within the range of about 1 to about 7 weight percent, the additive amount can be about 2 to about 5 weight percent, specifically about 2 to about 4 weight percent.

There are a variety of ways in which the dispersion can be used to form a polymer composition. In some embodiments, the dispersion is melt blended with a polymer to form a polymer-based additive masterbatch, which is then compounded with additional polymer (which can be the same as or different from the polymer use to form the masterbatch) to form a final polymer composition. In these embodiments, the polymer-based additive masterbatch can, optionally, be isolated (e.g., cooled and pelletized) before it is used to form the final polymer composition. In other embodiments, the final polymer composition is formed directly by melt blending the dispersion with polymer and any other components. In these embodiments, melt blending can be conducted in a single extruder or in two or more extruders. When two or more extruders are used, the extrudate formed by the first extruder can, optionally, be isolated (e.g., cooled and pelletized) prior to processing by the second extruder. In other embodiments, all components of the final polymer composition other than the dispersion are melt blended to form a polymer pre-blend, and the polymer pre-blend is then melt blended with the dispersion to form the final polymer composition. In these embodiments, the polymer pre-blend can, optionally, be isolated (e.g., cooled and pelletized) prior to melt blending with the dispersion.

The invention extends to the dispersion itself. Thus, one embodiment is a dispersion, comprising: about 83 to about 98 weight percent of water; about 1 to about 10 weight percent of an unmodified clay; and about 1 to about 7 weight percent of carbon nanotubes; wherein the weight percents of the water, the unmodified clay, and the carbon nanotubes are based on the weight of the dispersion. Within the range of about 83 to about 98 weight percent, the water amount can be about 87 to about 96 weight percent, specifically about 91 to about 94 weight percent. Within the range of about 1 to about 10 weight percent, the unmodified clay amount can be about 2 to about 8 weight percent, specifically about 3 to about 6 weight percent, more specifically about 3 to about 5 weight percent. Within the range of about 1 to about 7 weight percent, the carbon nanotube amount can be about 2 to about 5 weight percent, specifically about 2 to about 4 weight percent. All of the variations of the unmodified clay described above in the context of the method are applicable as well to the dispersion itself. For example, in some embodiments, the unmodified clay comprises montmorillonite.

Other embodiments include polymer compositions prepared according to the above-described methods, polymer compositions obtainable by the above methods, and articles comprising the polymer compositions. The phrase “polymer compositions obtainable by the above methods” includes not only polymer compositions that are literally prepared by the above-described methods, but also polymer compositions prepared by other methods that have substantially the same compositions, morphologies, and properties as compositions prepared by the above-described methods.

Useful articles that can be prepared from the composition include electrical and automotive connectors, electrical devices such as switches, and electrical enclosures such as junction boxes, lighting enclosures, and sockets. Injection molding is a presently preferred method of forming articles from the composition.

The invention includes at least the following embodiments.

Embodiment 1: A method of incorporating an additive into a polymer composition, comprising: melt blending a polymer with a dispersion comprising a liquid carrier, an unmodified clay, and an additive.

Embodiment 2: The method of embodiment 1, wherein the melt blending the polymer with the dispersion is conducted under conditions effective to evaporate the liquid carrier.

Embodiment 3: The method of embodiment 1 or 2, wherein the polymer is selected from the group consisting of polyesters, melamines, poly(vinyl chloride)s, polystyrenes, polyethylenes, chlorinated polyethylenes, polytetrachloroethylenes, polypropylenes, polycarbonates, polyimides, polyetherimides, poly(ether ether ketone)s, polysulfones, poly(arylene ether)s, polyamides, copolymers of styrene and acrylonitrile, copolymers of alpha-methylstyrene and acrylonitrile, copolymers of acrylonitrile and butadiene and styrene, copolymers of acrylonitrile and styrene and acrylate esters, polyacetals, copolymers of ethylene and polytetrafluoroethylene, rubber-modified polystyrenes, polyurethanes, and combinations thereof.

Embodiment 4: The method of any of embodiments 1-3, wherein the liquid carrier is selected from the group consisting of water, C₁-C₁₈ alcohols, C₂-C₁₈ aldehydes, C₃-C₁₈ ketones, C₃-C₁₈ esters, C₂-C₁₈ ethers, mineral oils, organic oils, C₄-C₁₈ aliphatic hydrocarbon solvents, C₆-C₁₈ aromatic hydrocarbon solvents, liquidized gases, and mixtures thereof.

Embodiment 5: The method of any of embodiments 1-4, wherein the liquid carrier comprises water.

Embodiment 6: The method of any of embodiments 1-5, wherein the unmodified clay is selected from the group consisting of kaolinite, dicktite, nacrite, pyrophyillite, talc, vermiculite, sauconite, saponite, nontronite, montmorillonite, illite, amesite, baileychlore, chamosite, clinochlore (kaemmererite), cookeite, corundophilite, daphnite, delessite, gonyerite, nimite, odinite, orthochamosite, penninite, pannantite, rhipidolite (prochlore), sudoite, thuringite, and mixtures thereof.

Embodiment 7: The method of any of embodiments 1-6, wherein the unmodified clay comprises montmorillonite.

Embodiment 8: The method of any of embodiments 1-7, wherein the additive is selected from the group consisting of colorants, electrically conductive agents, stabilizers, antioxidants, mold release agents, flame retardants, drip retardants, UV blockers, fragrances, anti-static agents, metal deactivators, antiblocking agents, impact modifiers, and fillers.

Embodiment 9: The method of any of embodiments 1-8, wherein the additive comprises conductive carbon black, carbon nanotubes, or a combination thereof.

Embodiment 10: The method of any of embodiments 1-9, wherein the additive comprises carbon nanotubes.

Embodiment 11: The method of any of embodiments 1-10, wherein the dispersion has a viscosity of about 10 to about 1,000,000 centipoise at 25° C. and a shear rate in the range of about 50 to about 450 sec⁻¹.

Embodiment 12: The method of any of embodiments 1-11, wherein the dispersion comprises about 80 to about 98.9 weight percent of the liquid carrier, about 1 to about 10 weight percent of the unmodified clay, and about 0.1 to about 10 weight percent of the additive, wherein the weight percents of the liquid carrier, the unmodified clay, and the additive are based on the weight of the dispersion.

Embodiment 13: The method of embodiment 1, wherein the dispersion comprises about 83 to about 98 weight percent of the liquid carrier; wherein the liquid carrier comprises water wherein the dispersion comprises about 1 to about 10 weight percent of the unmodified clay; wherein the unmodified clay comprises montmorillonite; wherein the dispersion comprises about 1 to about 7 weight percent of the additive; wherein the additive comprises carbon nanotubes; and wherein the weight percents of the liquid carrier, the unmodified clay, and the additives are based on the weight of the dispersion.

Embodiment 14: A dispersion, comprising: about 83 to about 98 weight percent of water; about 1 to about 10 weight percent of an unmodified clay; and about 1 to about 7 weight percent of carbon nanotubes; wherein the weight percents of the water, the unmodified clay, and the carbon nanotubes are based on the weight of the dispersion.

Embodiment 15: The dispersion of embodiment 14, wherein the unmodified clay comprises montmorillonite.

Embodiment 16: A polymer composition prepared by the method of embodiment 1.

Embodiment 17: A polymer composition prepared by the method of embodiment 13.

Embodiment 18: A polymer composition obtainable by the method of embodiment 1.

Embodiment 19: A polymer composition obtainable by the method of embodiment 13.

Embodiment 20: An article comprising the composition of embodiment 16.

Embodiment 21: An article comprising the composition of embodiment 17.

Embodiment 22: An article comprising the composition of embodiment 18.

Embodiment 23: An article comprising the composition of embodiment 19.

The invention is further illustrated by the following non-limiting examples.

EXAMPLE 1, COMPARATIVE EXAMPLES 1-3

These examples describe the preparation of electrically conductive poly(arylene ether)-polyamide compositions by various methods. Components used in the working examples are summarized in Table 1.

TABLE 1 Component Description PPE Poly(2,6-dimethyl-1,4-phenylene ether) (CAS Reg. No. 25134-01-4) having an intrinsic viscosity of about 0.4 deciliter per gram, measured at 25° C. in chloroform; obtained from SABIC Innovative Plastics as PPO 803 PA66 Polyamide-6,6 (CAS Reg. No. 32131-17-2) having a reduced viscosity of about 120-130 milliliters/gram and an amino endgroup concentration of about 40-60 milliequivalents/ gram; obtained from Rhodia PA6 Polyamide-6 (CAS Reg. No. 25038-54-5), having a reduced viscosity of about 110-140 milliliters/gram and an amino endgroup concentration of about 90-110 milliequivalents/ gram; obtained from Rhodia SEBS Polystyrene-poly(ethylene-butylene)- polystyrene triblock copolymer (CAS Reg. No. 66070-58-4) having a polystyrene content of about 30-33 weight percent; obtained from Kraton Polymers as KRATON G1651 SEP Polystyrene-poly(ethylene-propylene) diblock copolymer (CAS Reg. No. 68648-89-5) having a polystyrene content of about 37 weight percent; obtained from Kraton Polymers as KRATON G1701 CA Citric acid (CAS Reg. No. 77-92-9), obtained from Jungbunzlauer Stabilizer A hindered phenol stabilizer, octadecyl 3- (3,5-di-tert-butyl-4-hydroxyphenyl)propionate (CAS Reg. No. 2082-79-3), obtained from Ciba as IRGANOX 1076 KI soln. Potassium iodide (CAS Reg. No. 7681-11-0) 50 weight percent solution in water CuI Cuprous iodide (CAS Reg. No. 7681-65-4) CB Conductive carbon black (CAS Reg. No. 133-86-4); obtained from AkzoNobel as KETJENBLACK EC-600JD CNT Multiwall carbon nanotubes (CAS Reg. Nos. 7440-44-0, 7782-42-5) having an average diameter of about 9.5 nanometers, an average length of about 1.5 micrometers, a carbon content of about 90 weight percent, a metal oxide content of about 10 weight percent, and a BET surface area of about 250-300 meter2/gram; obtained from Nanocyl as NANOCYL NC7000 CNT/PA Masterbatch of 20 weight percent multiwall carbon nanotubes in polyamide-6,6; obtained from Hyperion Catalysis as MB4620-00 Clay Natural (unmodified) montmorillonite clay (CAS Reg. No. 1302-78-9), obtained from Southern Clay Products as CLOISITE Na+ CNT/clay/PA Masterbatch of 3.5 weight percent multiwall carbon nanotubes and 7 weight percent clay in polyamide-6,6 CNT/clay/H₂O Dispersion of 3 weight percent carbon nanotubes and 4 weight percent clay in water

The extruder used for all experiments was a Werner and Pfleiderer twin-screw extruder with a diameter of 28 millimeters, operating at a cylinder temperature of 300° C.

In a first experiment (Comparative Example 1), poly(arylene ether) and citric acid were introduced together with two impact modifiers and stabilizers at the throat of the extruder. Using a feedport located approximately ⅓ downstream the length of the extruder, polyamide-6 and polyamide-6,6 were added. Using a feedport approximately ⅔ downstream the length of the extruder, a conductive carbon black was added.

In a second experiment (Comparative Example 2), poly(arylene ether) and citric acid were introduced together with two impact modifiers and stabilizers at the throat of the extruder. Using a feedport located approximately ⅓ downstream the length of the extruder, polyamide-6,6 and a masterbatch consisting of 80 weight percent polyamide-6,6 and 20 weight percent multiwall carbon nanotubes were added.

In a third experiment (Example 1), poly(arylene ether) and citric acid were introduced together with two impact modifiers and stabilizers at the throat of the extruder. Using a feedport located approximately ⅓ downstream the length of the extruder, polyamide 6 and a masterbatch consisting of 89.5 weight percent polyamide-6,6, 3.5 weight percent multiwall carbon nanotubes, 7 weight percent of clay were added. This masterbatch was produced by compounding (melt blending) polyamide-6,6 with a dispersion containing carbon nanotubes, clay, and water. The dispersion of carbon nanotubes, clay, water was produced as follows. Unmodified clay and carbon nanotubes were added to water in such a way that first half of the clay and then all of the carbon nanotubes are added to 70% of the necessary water. After addition of the second half of the clay the rest of the water is added. The components are mixed in a steel bucket with a standard mixer device driven by an electric drill. The dispersion is prepared one day in advance. While not wishing to be bound by any particular theory of operation, the inventors believe that the dispersion of clay is enhanced by the one day aging because the water has time to diffuse into the agglomerates and swell the clay to nearly the same extend over the whole dispersion. This causes that in the distribution step nearly no agglomerates have to be destroyed (dispersed) and distributed in the polymer (here, dispersion means separation of single platelets of the clay and distribution means arranging particles in the polymer matrix. The aging can be accelerated by using hot water and a high shear mixing device for preparing the dispersion, in which case the one day aging can be reduced to two hours or even less. On aging, the dispersion becomes stiff, but after some mixing it becomes less viscous again. During the aging the so-called card house structure is formed by hydrogen bonding of the edges of clay to each other. By mixing again this card house structure is destroyed and the dispersion become fluid.

After the dispersion is prepared, the masterbatch is prepared as follows. The extruder used for masterbatch preparation is a 27 millimeter twin-screw extruder from Leistritz. The extruder has 11 barrels. Polyamide-6,6 is added at the first barrel and the dispersion is added at the fifth barrel. At the fourth barrel there is an atmospheric vent and at the ninth barrel there is a ventport maintained at an absolute pressure of about 50 millibar (5 kilopascals). The dispersion is added at a point where the screw is not completely filled. All barrels are maintained at a temperature of 270° C., and the barrels around the point where the dispersion is added are equipped with electrical heating with a higher power. The higher heating power is intended to compensate for the cooling associated with water evaporation. The dispersion is added using a Seepex screw-feeder with a hopper on it. The feeder is connected to the extruder with some tubing and an injector. The injector does not contain a piston that only opens the injector at a certain pressure; instead the injector has a relatively large opening. Before the experiment is started the feeder is calibrated by running for a short period at a certain screwspeed and weighing the collected material out of the injector. It is preferred that there is no entrained air in the dispersion because this can result in an irregular flow out of the injector and prohibit developing the necessary pressure for injection into the melt. During the experiment the dispersion is frequently pushed down in the hopper, as it does not always flow down by itself. Also the dispersion level in the hopper is kept approximately constant by topping off in order to keep the pressure of the dispersion more or less constant.

It is important to note that unmodified clay is used to prepare the dispersions of the inventive examples, as modified clays (so-called organoclays) may interfere with the poly(arylene ether)-polyamide compatibilization reaction and/or may not survive the very high compounding temperatures required in the manufacturing process of such blends.

Although small variations in component amounts preclude rigorous pair-wise comparisons, the results generally illustrate that the dispersion method of the present invention makes it possible to prepare conductive polymer compositions having properties similar to those of corresponding compositions prepared using conventional polymer-based masterbatches of conductive fillers.

TABLE 2 C. Ex. 1 C. Ex. 2 Ex. 1 COMPONENTS added at feedthroat PPE 35.19 38.49 36.89 SEBS 7 7 7 SEP 7 3.5 7 CA 0.7 0.7 0.7 Stabilizer 0.3 0.3 0.3 KI soln. 0.1 0.1 0.1 CuI 0.01 0.01 0.01 CB 1.7 0 0 added at side feeder PA6 10 0 10 PA66 38 44.4 0 CNT/PA 0 5.5 0 CNT/clay/PA 0 0 38 added at dispersion feeder CNT/clay/H₂O 0 0 0 PROPERTIES Volume resistivity (ohm-cm) 2,500 2,500 1,000 Tensile modulus (MPa) 2100 2100 2300 Tensile elongation at break (%) 30 40 25 Notched Izod impact (kJ/m²) 17 20 16 Vicat temperature (° C.) 180 192 184

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

All cited patents, patent applications, and other references are incorporated herein by reference in their entirety. However, if a term in the present application contradicts or conflicts with a term in the incorporated reference, the term from the present application takes precedence over the conflicting term from the incorporated reference.

All ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other.

The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Further, it should further be noted that the terms “first,” “second,” and the like herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The modifier “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., it includes the degree of error associated with measurement of the particular quantity). 

The invention claimed is:
 1. A method of incorporating an additive into a polymer composition, comprising: melt blending a polymer with a dispersion comprising a liquid carrier, an unmodified clay, and an additive; wherein the additive comprises conductive carbon black, carbon nanotubes, or a combination thereof.
 2. The method of claim 1, wherein the melt blending the polymer with the dispersion is conducted under conditions effective to evaporate the liquid, carrier.
 3. The method of claim 1, wherein the polymer is selected from the group consisting of polyesters, melamines, poly(vinyl chloride)s, polystyrenes, polyethylenes, chlorinated polyethylenes, polytetrachloroethylenes, polypropylenes, polycarbonates, polyimides, polyetherimides, poly(ether ether ketone)s, polysulfones, poly(arylene ether)s, polyamides, copolymers of styrene and acrylonitrile, copolymers of alpha-methylstyrene and acrylonitrile, copolymers of acrylonitrile and butadiene and styrene, copolymers of acrylonitrile and styrene and acrylate esters, polyacetals, copolymers of ethylene and polytetrafluoroethylene, rubber-modified polystyrenes, polyurethanes, and combinations thereof.
 4. The method of claim 1, wherein the liquid carrier is selected from the group consisting of water, C₁-C₁₈ alcohols, C₂-C₁₈ aldehydes, C₃-C₁₈ ketones, C₃-C₁₈ esters, C₂-C₁₈ ethers, mineral oils, organic oils, C₄-C₁₈ aliphatic hydrocarbon solvents, C₆-C₁₈ aromatic hydrocarbon solvents, liquidized gases, and mixtures thereof.
 5. The method of claim 1, wherein the liquid carrier comprises water.
 6. The method of claim 1, wherein the unmodified clay is selected from the group consisting of kaolinite, dicktite, nacrite, pyrophyillite, talc, vermiculite, sauconite, saponite, nontronite, montmorillonite, illite, amesite, baileychlore, chamosite, clinochlore (kaemmererite), cookeite, corundophilite; daphnite, delessite, gonyerite, nimite, odinite, orthochamosite, penninite, pannantite, rhipidolite (prochlore), sudoite, thuringite, and mixtures thereof.
 7. The method of claim 1, wherein the unmodified clay comprises montmorillonite.
 8. The method of claim 1, wherein the additive comprises carbon nanotubes.
 9. The method of claim 1, wherein the dispersion has a viscosity of about 10 to about 1,000,000 centipoise at 25° C. and a shear rate in the range of about 50 to about 450 sec⁻¹.
 10. The method of claim 1, wherein the dispersion comprises about 80 to about 98.9 weight percent of the liquid carrier, about 1 to about 10 weight percent of the unmodified clay, and about 0.1 to about 10 weight percent of the additive, wherein the weight percents of the liquid carrier, the unmodified clay, and the additive are based on the weight of the dispersion.
 11. The method of claim 1, wherein the dispersion comprises about 83 to about 98 weight percent of the liquid carrier; wherein the liquid carrier comprises water wherein the dispersion comprises about 1 to about 10 weight percent of the unmodified clay; wherein the unmodified clay comprises montmorillonite; wherein the dispersion comprises about 1 to about 7 weight percent of the additive; wherein the additive comprises carbon nanotubes; and wherein the weight percents of the liquid carrier, the unmodified clay, and the additives are based on the weight of the dispersion. 